Refillable aerosol delivery device and related method

ABSTRACT

The present disclosure is directed to an aerosol delivery device. The aerosol delivery device may include one or more fill ports. Thereby, a reservoir of the aerosol delivery device may be refillable. The fill ports may be defined in a base of a cartridge of the aerosol delivery device. The aerosol delivery device may further include a flow director. An atomizer may extend through the flow director transversely to a longitudinal length of the flow director. The atomizer may include a liquid transport element with a capillary channel extending therethrough, which may receive aerosol precursor composition from the reservoir. There aerosol precursor composition may be drawn through the liquid transport element to a heating element of the atomizer, which may vaporize the aerosol precursor composition.

BACKGROUND Field of the Disclosure

The present disclosure relates to aerosol delivery devices such aselectronic cigarettes, and more particularly to aerosol delivery devicesincluding an atomizer. The atomizer may be configured to heat an aerosolprecursor composition, which may be made or derived from tobacco orotherwise incorporate tobacco, to form an inhalable substance for humanconsumption.

Description of Related Art

Many devices have been proposed through the years as improvements upon,or alternatives to, smoking products that require combusting tobacco foruse. Many of those devices purportedly have been designed to provide thesensations associated with cigarette, cigar, or pipe smoking, butwithout delivering considerable quantities of incomplete combustion andpyrolysis products that result from the burning of tobacco. To this end,there have been proposed numerous alternative smoking products, flavorgenerators, and medicinal inhalers that utilize electrical energy tovaporize or heat a volatile material, or attempt to provide thesensations of cigarette, cigar, or pipe smoking without burning tobaccoto a significant degree. See, for example, the various alternativesmoking articles, aerosol delivery devices and heat generating sourcesset forth in the background art described in U.S. Pat. No. 8,881,737 toCollett et al., U.S. Pat. App. Pub. No. 2013/0255702 to Griffith Jr. etal., U.S. Pat. App. Pub. No. 2014/0000638 to Sebastian et al., U.S. Pat.App. Pub. No. 2014/0096781 to Sears et al., U.S. Pat. App. Pub. No.2014/0096782 to Ampolini et al., and U.S. Pat. App. Pub. No.2015/0059780 to Davis et al., which are incorporated herein by referencein their entireties. See also, for example, the various embodiments ofproducts and heating configurations described in the background sectionsof U.S. Pat. No. 5,388,594 to Counts et al. and U.S. Pat. No. 8,079,371to Robinson et al., which are incorporated by reference in theirentireties.

However, it may be desirable to provide aerosol delivery devices withalternate configurations. Such configurations may provide for refillingand reuse of the aerosol delivery device. Thus, advances with respect toaerosol delivery devices may be desirable.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure relates to aerosol delivery devices configured toproduce aerosol and which aerosol delivery devices, in some embodiments,may be referred to as electronic cigarettes. In one aspect, an aerosoldelivery device is provided. The aerosol delivery device may include anouter body, a base, and a flow director extending from a first flowdirector end to a second flow director end through the outer body suchthat a reservoir may be defined between the flow director and the outerbody. The reservoir may define an open space configured to receive anaerosol precursor composition. Additionally, the aerosol delivery devicemay include an atomizer extending through the flow director at aposition between the first flow director end and the second flowdirector end. The atomizer may include a liquid transport element and aheating element configured to vaporize at least a portion of the aerosolprecursor composition to produce an aerosol within the flow director.

In some embodiments the liquid transport element may include a capillarychannel extending therethrough. The liquid transport element may includea porous monolith. The heating element may include a wire defining aplurality of coils extending around the liquid transport element. Theaerosol delivery device may additionally include first and secondconnectors contacting the coils at first and second opposing ends of theheating element.

In some embodiments a longitudinal axis of the liquid transport elementmay extend substantially perpendicularly to a longitudinal axis of theflow director. The outer body may be sealed to the base. The outer bodymay engage the base via threaded engagement. The aerosol delivery devicemay additionally include an O-ring compressed between the outer body andthe base. The aerosol delivery device may further include a mouthpiece.The mouthpiece may be sealed to the outer body and the flow director.The base may include one or more fill ports configured to receive theaerosol precursor composition therethrough. The atomizer may be sealedto the flow director.

In an additional aspect, an aerosol delivery device operation method isprovided. The method may include retaining an aerosol precursorcomposition in a reservoir defined between a flow director and an outerbody. The flow director may extend between a first flow director end anda second flow director end. Further, the method may include directingthe aerosol precursor composition from the reservoir through a liquidtransport element of an atomizer extending through the flow director ata position between the first flow director end and the second flowdirector end. The method may additionally include receiving anelectrical current through a heating element of the atomizer. The methodmay further include vaporizing at least a portion of the aerosolprecursor composition to produce an aerosol within the flow director.

In some embodiments, the method may further include receiving theaerosol precursor composition through one or more fill ports defined ina base. Directing the aerosol precursor composition through the liquidtransport element may include directing the aerosol precursorcomposition through a capillary channel. Directing the aerosol precursorcomposition through the liquid transport element may further includedirecting the aerosol precursor composition through a porous monolith tothe heating element.

In some embodiments receiving the electrical current through the heatingelement may include receiving the electrical current through a wiredefining a plurality of coils extending around the liquid transportelement. Additionally, the method may include directing the aerosol outof the flow director through a mouthpiece. The method may furtherinclude retaining the aerosol precursor composition in the reservoirwith a seal between the outer body and the base. The method mayadditionally include retaining the aerosol precursor composition in thereservoir with a seal between the mouthpiece and the outer body and aseal between the mouthpiece and the flow director.

These and other features, aspects, and advantages of the disclosure willbe apparent from a reading of the following detailed descriptiontogether with the accompanying drawings, which are briefly describedbelow.

BRIEF DESCRIPTION OF THE FIGURES

Having thus described the disclosure in the foregoing general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 illustrates a side view of an aerosol delivery device comprisinga cartridge and a control body in an assembled configuration accordingto an example embodiment of the present disclosure;

FIG. 2 illustrates the control body of FIG. 1 in an explodedconfiguration according to an example embodiment of the presentdisclosure;

FIG. 3 illustrates the cartridge of FIG. 1 in an exploded configurationaccording to an example embodiment of the present disclosure;

FIG. 4 illustrates a partially-exploded view of a refillable cartridgeaccording to an example embodiment of the present disclosure;

FIG. 5 illustrates the refillable cartridge of FIG. 4 in an assembledconfiguration;

FIG. 6 illustrates an enlarged perspective view of an atomizer of therefillable cartridge of FIG. 4;

FIG. 7 illustrates a partial longitudinal sectional view through a lowerportion of the cartridge of FIG. 4;

FIG. 8 illustrates a partial longitudinal sectional view through anupper portion of the cartridge of FIG. 4; and

FIG. 9 schematically illustrates an aerosol delivery device operationmethod according to an example embodiment of the present disclosure.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present disclosure will now be described more fully hereinafter withreference to exemplary embodiments thereof. These exemplary embodimentsare described so that this disclosure will be thorough and complete, andwill fully convey the scope of the disclosure to those skilled in theart. Indeed, the disclosure may be embodied in many different forms andshould not be construed as limited to the embodiments set forth herein;rather, these embodiments are provided so that this disclosure willsatisfy applicable legal requirements. As used in the specification, andin the appended claims, the singular forms “a”, “an”, “the”, includeplural variations unless the context clearly dictates otherwise.

The present disclosure provides descriptions of aerosol deliverydevices. The aerosol delivery devices may use electrical energy to heata material (preferably without combusting the material to anysignificant degree) to form an inhalable substance; such articles mostpreferably being sufficiently compact to be considered “hand-held”devices. An aerosol delivery device may provide some or all of thesensations (e.g., inhalation and exhalation rituals, types of tastes orflavors, organoleptic effects, physical feel, use rituals, visual cuessuch as those provided by visible aerosol, and the like) of smoking acigarette, cigar, or pipe, without any substantial degree of combustionof any component of that article or device. The aerosol delivery devicemay not produce smoke in the sense of the aerosol resulting fromby-products of combustion or pyrolysis of tobacco, but rather, that thearticle or device most preferably yields vapors (including vapors withinaerosols that can be considered to be visible aerosols that might beconsidered to be described as smoke-like) resulting from volatilizationor vaporization of certain components of the article or device, althoughin other embodiments the aerosol may not be visible. In highly preferredembodiments, aerosol delivery devices may incorporate tobacco and/orcomponents derived from tobacco. As such, the aerosol delivery devicecan be characterized as an electronic smoking article such as anelectronic cigarette or “e-cigarette.”

While the systems are generally described herein in terms of embodimentsassociated with aerosol delivery devices such as so-called“e-cigarettes,” it should be understood that the mechanisms, components,features, and methods may be embodied in many different forms andassociated with a variety of articles. For example, the descriptionprovided herein may be employed in conjunction with embodiments oftraditional smoking articles (e.g., cigarettes, cigars, pipes, etc.),heat-not-burn cigarettes, and related packaging for any of the productsdisclosed herein. Accordingly, it should be understood that thedescription of the mechanisms, components, features, and methodsdisclosed herein are discussed in terms of embodiments relating toaerosol delivery devices by way of example only, and may be embodied andused in various other products and methods.

Aerosol delivery devices of the present disclosure also can becharacterized as being vapor-producing articles or medicament deliveryarticles. Thus, such articles or devices can be adapted so as to provideone or more substances (e.g., flavors and/or pharmaceutical activeingredients) in an inhalable form or state. For example, inhalablesubstances can be substantially in the form of a vapor (i.e., asubstance that is in the gas phase at a temperature lower than itscritical point). Alternatively, inhalable substances can be in the formof an aerosol (i.e., a suspension of fine solid particles or liquiddroplets in a gas). For purposes of simplicity, the term “aerosol” asused herein is meant to include vapors, gases and aerosols of a form ortype suitable for human inhalation, whether or not visible, and whetheror not of a form that might be considered to be smoke-like.

In use, aerosol delivery devices of the present disclosure may besubjected to many of the physical actions employed by an individual inusing a traditional type of smoking article (e.g., a cigarette, cigar orpipe that is employed by lighting and inhaling tobacco). For example,the user of an aerosol delivery device of the present disclosure canhold that article much like a traditional type of smoking article, drawon one end of that article for inhalation of aerosol produced by thatarticle, take puffs at selected intervals of time, etc.

Aerosol delivery devices of the present disclosure generally include anumber of components provided within an outer shell or body. The overalldesign of the outer shell or body can vary, and the format orconfiguration of the outer body that can define the overall size andshape of the aerosol delivery device can vary. Typically, an elongatedbody resembling the shape of a cigarette or cigar can be a formed from asingle, unitary shell; or the elongated body can be formed of two ormore separable pieces. For example, an aerosol delivery device cancomprise an elongated shell or body that can be substantially tubular inshape and, as such, resemble the shape of a conventional cigarette orcigar. However, various other shapes and configurations may be employedin other embodiments (e.g., rectangular or fob-shaped).

In one embodiment, all of the components of the aerosol delivery deviceare contained within one outer body or shell. Alternatively, an aerosoldelivery device can comprise two or more shells that are joined and areseparable. For example, an aerosol delivery device can possess at oneend a control body comprising a shell containing one or more reusablecomponents (e.g., a rechargeable battery and various electronics forcontrolling the operation of that article), and at the other end andremovably attached thereto a shell containing a disposable portion(e.g., a disposable flavor-containing cartridge). More specific formats,configurations and arrangements of components within the single shelltype of unit or within a multi-piece separable shell type of unit willbe evident in light of the further disclosure provided herein.Additionally, various aerosol delivery device designs and componentarrangements can be appreciated upon consideration of the commerciallyavailable electronic aerosol delivery devices.

Aerosol delivery devices of the present disclosure most preferablycomprise some combination of a power source (i.e., an electrical powersource), at least one control component (e.g., means for actuating,controlling, regulating and/or ceasing power for heat generation, suchas by controlling electrical current flow from the power source to othercomponents of the aerosol delivery device), a heater or heat generationcomponent (e.g., an electrical resistance heating element or componentcommonly referred to as part of an “atomizer”), and an aerosol precursorcomposition (e.g., commonly a liquid capable of yielding an aerosol uponapplication of sufficient heat, such as ingredients commonly referred toas “smoke juice,” “e-liquid” and “e-juice”), and a mouthend region ortip for allowing draw upon the aerosol delivery device for aerosolinhalation (e.g., a defined air flow path through the article such thataerosol generated can be withdrawn therefrom upon draw).

Alignment of the components within the aerosol delivery device of thepresent disclosure can vary. In specific embodiments, the aerosolprecursor composition can be located near an end of the aerosol deliverydevice which may be configured to be positioned proximal to the mouth ofa user so as to maximize aerosol delivery to the user. Otherconfigurations, however, are not excluded. Generally, the heatingelement can be positioned sufficiently near the aerosol precursorcomposition so that heat from the heating element can volatilize theaerosol precursor (as well as one or more flavorants, medicaments, orthe like that may likewise be provided for delivery to a user) and forman aerosol for delivery to the user. When the heating element heats theaerosol precursor composition, a vapor is formed with subsequentlycondenses to an aerosol suitable for inhalation by a consumer. It shouldbe noted that the foregoing terms are meant to be interchangeable suchthat reference to release, releasing, releases, or released includesform or generate, forming or generating, forms or generates, and formedor generated. Specifically, an inhalable substance is released in theform of a vapor or aerosol or mixture thereof, wherein such terms arealso interchangeably used herein except where otherwise specified.

As noted above, the aerosol delivery device may incorporate a batteryand/or other electrical power source (e.g., a capacitor) to providecurrent flow sufficient to provide various functionalities to theaerosol delivery device, such as powering of a heater, powering ofcontrol systems, powering of indicators, and the like. The power sourcecan take on various embodiments. Preferably, the power source is able todeliver sufficient power to rapidly heat the heating element to providefor aerosol formation and power the aerosol delivery device through usefor a desired duration of time. The power source preferably is sized tofit conveniently within the aerosol delivery device so that the aerosoldelivery device can be easily handled. Additionally, a preferred powersource is of a sufficiently light weight to not detract from a desirablesmoking experience.

More specific formats, configurations and arrangements of componentswithin the aerosol delivery device of the present disclosure will beevident in light of the further disclosure provided hereinafter.Additionally, the selection of various aerosol delivery devicecomponents can be appreciated upon consideration of the commerciallyavailable electronic aerosol delivery devices. Further, the arrangementof the components within the aerosol delivery device can also beappreciated upon consideration of the commercially available electronicaerosol delivery devices. Examples of commercially available products,for which the components thereof, methods of operation thereof,materials included therein, and/or other attributes thereof may beincluded in the devices of the present disclosure as well asmanufacturers, designers, and/or assignees of components and relatedtechnologies that may be employed in the aerosol delivery device of thepresent disclosure are described in U.S. patent application Ser. No.15/222,615, filed Jul. 28, 2016, to Watson et al., which is incorporatedherein by reference in its entirety.

One example embodiment of an aerosol delivery device 100 is illustratedin FIG. 1. In particular, FIG. 1 illustrates an aerosol delivery device100 including a control body 200 and a cartridge 300. The control body200 and the cartridge 300 can be permanently or detachably aligned in afunctioning relationship. Various mechanisms may connect the cartridge300 to the control body 200 to result in a threaded engagement, apress-fit engagement, an interference fit, a magnetic engagement, or thelike. The aerosol delivery device 100 may be substantially rod-like,substantially tubular shaped, or substantially cylindrically shaped insome embodiments when the cartridge 300 and the control body 200 are inan assembled configuration. However, as noted above, various otherconfigurations such as rectangular or fob-shaped may be employed inother embodiments. Further, although the aerosol delivery devices aregenerally described herein as resembling the size and shape of atraditional smoking article, in other embodiments differingconfigurations and larger capacity reservoirs, which may be referred toas “tanks,” may be employed.

In specific embodiments, one or both of the cartridge 300 and thecontrol body 200 may be referred to as being disposable or as beingreusable. For example, the control body 200 may have a replaceablebattery or a rechargeable battery and/or capacitor and thus may becombined with any type of recharging technology, including connection toa typical alternating current electrical outlet, connection to a carcharger (i.e., cigarette lighter receptacle), and connection to acomputer, such as through a universal serial bus (USB) cable. Further,in some embodiments the cartridge 300 may comprise a single-usecartridge, as disclosed in U.S. Pat. No. 8,910,639 to Chang et al.,which is incorporated herein by reference in its entirety.

FIG. 2 illustrates an exploded view of the control body 200 of theaerosol delivery device 100 (see, FIG. 1) according to an exampleembodiment of the present disclosure. As illustrated, the control body200 may comprise a coupler 202, an outer body 204, a sealing member 206,an adhesive member 208 (e.g., KAPTON® tape), a flow sensor 210 (e.g., apuff sensor or pressure switch), a control component 212, a spacer 214,an electrical power source 216 (e.g., a capacitor and/or a battery,which may be rechargeable), a circuit board with an indicator 218 (e.g.,a light emitting diode (LED)), a connector circuit 220, and an end cap222. Examples of electrical power sources are described in U.S. Pat. No.9,484,155 to Peckerar et al., the disclosure of which is incorporatedherein by reference in its entirety.

With respect to the flow sensor 210, representative current regulatingcomponents and other current controlling components including variousmicrocontrollers, sensors, and switches for aerosol delivery devices aredescribed in U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. Nos.4,922,901, 4,947,874, and 4,947,875, all to Brooks et al., U.S. Pat. No.5,372,148 to McCafferty et al., U.S. Pat. No. 6,040,560 to Fleischhaueret al., U.S. Pat. No. 7,040,314 to Nguyen et al., and U.S. Pat. No.8,205,622 to Pan, all of which are incorporated herein by reference intheir entireties. Reference also is made to the control schemesdescribed in U.S. Pat. No. 9,423,152 to Ampolini et al., which isincorporated herein by reference in its entirety.

In one embodiment the indicator 218 may comprise one or more lightemitting diodes. The indicator 218 can be in communication with thecontrol component 212 through the connector circuit 220 and beilluminated, for example, during a user draw on a cartridge coupled tothe coupler 202, as detected by the flow sensor 210. The end cap 222 maybe adapted to make visible the illumination provided thereunder by theindicator 218. Accordingly, the indicator 218 may be illuminated duringuse of the aerosol delivery device 100 to simulate the lit end of asmoking article. However, in other embodiments the indicator 218 can beprovided in varying numbers and can take on different shapes and caneven be an opening in the outer body (such as for release of sound whensuch indicators are present).

Still further components can be utilized in the aerosol delivery deviceof the present disclosure. For example, U.S. Pat. No. 5,154,192 toSprinkel et al. discloses indicators for smoking articles; U.S. Pat. No.5,261,424 to Sprinkel, Jr. discloses piezoelectric sensors that can beassociated with the mouth-end of a device to detect user lip activityassociated with taking a draw and then trigger heating of a heatingdevice; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puffsensor for controlling energy flow into a heating load array in responseto pressure drop through a mouthpiece; U.S. Pat. No. 5,967,148 to Harriset al. discloses receptacles in a smoking device that include anidentifier that detects a non-uniformity in infrared transmissivity ofan inserted component and a controller that executes a detection routineas the component is inserted into the receptacle; U.S. Pat. No.6,040,560 to Fleischhauer et al. describes a defined executable powercycle with multiple differential phases; U.S. Pat. No. 5,934,289 toWatkins et al. discloses photonic-optronic components; U.S. Pat. No.5,954,979 to Counts et al. discloses means for altering draw resistancethrough a smoking device; U.S. Pat. No. 6,803,545 to Blake et al.discloses specific battery configurations for use in smoking devices;U.S. Pat. No. 7,293,565 to Griffen et al. discloses various chargingsystems for use with smoking devices; U.S. Pat. No. 8,402,976 toFernando et al. discloses computer interfacing means for smoking devicesto facilitate charging and allow computer control of the device; U.S.Pat. No. 8,689,804 to Fernando et al. discloses identification systemsfor smoking devices; and WO 2010/003480 by Flick discloses a fluid flowsensing system indicative of a puff in an aerosol generating system; allof the foregoing disclosures being incorporated herein by reference intheir entireties. Further examples of components related to electronicaerosol delivery articles and disclosing materials or components thatmay be used in the present article include U.S. Pat. No. 4,735,217 toGerth et al.; U.S. Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No.5,666,977 to Higgins et al.; U.S. Pat. No. 6,053,176 to Adams et al.;U.S. Pat. No. 6,164,287 to White; U.S. Pat. No. 6,196,218 to Voges; U.S.Pat. No. 6,810,883 to Felter et al.; U.S. Pat. No. 6,854,461 to Nichols;U.S. Pat. No. 7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi;U.S. Pat. No. 7,896,006 to Hamano; U.S. Pat. No. 6,772,756 to Shayan;U.S. Pat. Nos. 8,156,944 and 8,375,957 to Hon; U.S. Pat. No. 8,528,569to Newton; U.S. Pat. No. 8,707,965 to Newton; U.S. Pat. No. 8,794,231 toThorens et al.; U.S. Pat. No. 8,851,083 to Oglesby et al.; U.S. Pat.Nos. 8,915,254 and 8,925,555 to Monsees et al.; and U.S. Pat. No.9,220,302 to DePiano et al.; U.S. Pat. App. Pub. Nos. 2006/0196518 and2009/0188490 to Hon; U.S. Pat. App. Pub. No. 2010/0024834 to Oglesby etal.; U.S. Pat. App. Pub. No. 2010/0307518 to Wang; WO 2010/091593 toHon; and WO 2013/089551 to Foo, each of which is incorporated herein byreference in its entirety. A variety of the materials disclosed by theforegoing documents may be incorporated into the present devices invarious embodiments, and all of the foregoing disclosures areincorporated herein by reference in their entireties.

FIG. 3 illustrates the cartridge 300 of the aerosol delivery device 100(see, FIG. 1) in an exploded configuration. As illustrated, thecartridge 300 may comprise a base 302, a control component terminal 304,an electronic component 306, a flow director 308, an atomizer 310, areservoir 312 (e.g., a reservoir substrate), an outer body 314, amouthpiece 316, a label 318, and first and second heating terminals 320,321 according to an example embodiment of the present disclosure.

In some embodiments the first and second heating terminals 320, 321 maybe embedded in, or otherwise coupled to, the flow director 308. Forexample, the first and second heating terminals 320, 321 may be insertmolded in the flow director 308. Accordingly, the flow director 308 andthe first and second heating terminals are collectively referred toherein as a flow director assembly 322. Additional description withrespect to the first and second heating terminals 320, 321 and the flowdirector 308 is provided in U.S. Pat. Pub. No. 2015/0335071 to Brinkleyet al., which is incorporated herein by reference in its entirety.

The atomizer 310 may comprise a liquid transport element 324 and aheating element 326. The cartridge may additionally include a baseshipping plug engaged with the base and/or a mouthpiece shipping plugengaged with the mouthpiece in order to protect the base and themouthpiece and prevent entry of contaminants therein prior to use asdisclosed, for example, in U.S. Pat. No. 9,220,302 to Depiano et al.,which is incorporated herein by reference in its entirety.

The base 302 may be coupled to a first end of the outer body 314 and themouthpiece 316 may be coupled to an opposing second end of the outerbody to substantially or fully enclose other components of the cartridge300 therein. For example, the control component terminal 304, theelectronic component 306, the flow director 308, the atomizer 310, andthe reservoir 312 may be substantially or entirely retained within theouter body 314. The label 318 may at least partially surround the outerbody 314, and optionally the base 302, and include information such as aproduct identifier thereon. The base 302 may be configured to engage thecoupler 202 of the control body 200 (see, e.g., FIG. 2). In someembodiments the base 302 may comprise anti-rotation features thatsubstantially prevent relative rotation between the cartridge and thecontrol body as disclosed in U.S. Pat. App. Pub. No. 2014/0261495 toNovak et al., which is incorporated herein by reference in its entirety.

The reservoir 312 may be configured to hold an aerosol precursorcomposition. Representative types of aerosol precursor components andformulations are also set forth and characterized in U.S. Pat. No.7,726,320 to Robinson et al., U.S. Pat. No. 8,881,737 to Collett et al.,and U.S. Pat. No. 9,254,002 to Chong et al.; and U.S. Pat. Pub. Nos.2013/0008457 to Zheng et al.; 2015/0020823 to Lipowicz et al.; and2015/0020830 to Koller, as well as WO 2014/182736 to Bowen et al, thedisclosures of which are incorporated herein by reference. Other aerosolprecursors that may be employed include the aerosol precursors that havebeen incorporated in the VUSE® product by R. J. Reynolds Vapor Company,the BLU product by Lorillard Technologies, the MISTIC MENTHOL product byMistic Ecigs, and the VYPE product by CN Creative Ltd. Also desirableare the so-called “smoke juices” for electronic cigarettes that havebeen available from Johnson Creek Enterprises LLC. Embodiments ofeffervescent materials can be used with the aerosol precursor, and aredescribed, by way of example, in U.S. Pat. App. Pub. No. 2012/0055494 toHunt et al., which is incorporated herein by reference. Further, the useof effervescent materials is described, for example, in U.S. Pat. No.4,639,368 to Niazi et al.; U.S. Pat. No. 5,178,878 to Wehling et al.;U.S. Pat. No. 5,223,264 to Wehling et al.; U.S. Pat. No. 6,974,590 toPather et al.; U.S. Pat. No. 7,381,667 to Bergquist et al.; U.S. Pat.No. 8,424,541 to Crawford et al; U.S. Pat. No. 8,627,828 to Stricklandet al.; and U.S. Pat. No. 9,307,787 to Sun et al.; as well as U.S. Pat.App. Pub. No. 2010/0018539 to Brinkley et al. and PCT WO 97/06786 toJohnson et al., all of which are incorporated by reference herein.Additional description with respect to embodiments of aerosol precursorcompositions, including description of tobacco or components derivedfrom tobacco included therein, is provided in U.S. patent applicationSer. Nos. 15/216,582 and 15/216,590, each filed Jul. 21, 2016 and eachto Davis et al., which are incorporated herein by reference in theirentireties.

The reservoir 312 may comprise a plurality of layers of nonwoven fibersformed into the shape of a tube encircling the interior of the outerbody 314 of the cartridge 300. Thus, liquid components, for example, canbe sorptively retained by the reservoir 312. The reservoir 312 is influid connection with the liquid transport element 324. Thus, the liquidtransport element 324 may be configured to transport liquid from thereservoir 312 to the heating element 326 via capillary action or otherliquid transport mechanism.

As illustrated, the liquid transport element 324 may be in directcontact with the heating element 326. As further illustrated in FIG. 3,the heating element 326 may comprise a wire defining a plurality ofcoils wound about the liquid transport element 324. In some embodimentsthe heating element 326 may be formed by winding the wire about theliquid transport element 324 as described in U.S. Pat. No. 9,210,738 toWard et al., which is incorporated herein by reference in its entirety.Further, in some embodiments the wire may define a variable coilspacing, as described in U.S. Pat. No. 9,277,770 to DePiano et al.,which is incorporated herein by reference in its entirety. Variousembodiments of materials configured to produce heat when electricalcurrent is applied therethrough may be employed to form the heatingelement 326. Example materials from which the wire coil may be formedinclude Kanthal (FeCrAl), Nichrome, Molybdenum disilicide (MoSi₂),molybdenum silicide (MoSi), Molybdenum disilicide doped with Aluminum(Mo(Si,Al)₂), graphite and graphite-based materials; and ceramic (e.g.,a positive or negative temperature coefficient ceramic).

However, various other embodiments of methods may be employed to formthe heating element 326, and various other embodiments of heatingelements may be employed in the atomizer 310. For example, a stampedheating element may be employed in the atomizer, as described in U.S.Pat. No. 9,491,974 to DePiano et al., which is incorporated herein byreference in its entirety. Further to the above, additionalrepresentative heating elements and materials for use therein aredescribed in U.S. Pat. No. 5,060,671 to Counts et al.; U.S. Pat. No.5,093,894 to Deevi et al.; U.S. Pat. No. 5,224,498 to Deevi et al.; U.S.Pat. No. 5,228,460 to Sprinkel Jr., et al.; U.S. Pat. No. 5,322,075 toDeevi et al.; U.S. Pat. No. 5,353,813 to Deevi et al.; U.S. Pat. No.5,468,936 to Deevi et al.; U.S. Pat. No. 5,498,850 to Das; U.S. Pat. No.5,659,656 to Das; U.S. Pat. No. 5,498,855 to Deevi et al.; U.S. Pat. No.5,530,225 to Hajaligol; U.S. Pat. No. 5,665,262 to Hajaligol; U.S. Pat.No. 5,573,692 to Das et al.; and U.S. Pat. No. 5,591,368 to Fleischhaueret al., the disclosures of which are incorporated herein by reference intheir entireties. Further, chemical heating may be employed in otherembodiments. Various additional examples of heaters and materialsemployed to form heaters are described in U.S. Pat. No. 8,881,737 toCollett et al., which is incorporated herein by reference, as notedabove.

A variety of heater components may be used in the present aerosoldelivery device. In various embodiments, one or more microheaters orlike solid state heaters may be used. Microheaters and atomizersincorporating microheaters suitable for use in the presently discloseddevices are described in U.S. Pat. No. 8,881,737 to Collett et al.,which is incorporated herein by reference in its entirety.

The first heating terminal 320 and the second heating terminal 321(e.g., negative and positive heating terminals) are configured to engageopposing ends of the heating element 326 and to form an electricalconnection with the control body 200 (see, e.g., FIG. 2) when thecartridge 300 is connected thereto. Further, when the control body 200is coupled to the cartridge 300, the electronic component 306 may forman electrical connection with the control body through the controlcomponent terminal 304. The control body 200 may thus employ theelectronic component 212 (see, FIG. 2) to determine whether thecartridge 300 is genuine and/or perform other functions. Further,various examples of electronic control components and functionsperformed thereby are described in U.S. Pat. App. Pub. No. 2014/0096781to Sears et al., which is incorporated herein by reference in itsentirety.

During use, a user may draw on the mouthpiece 316 of the cartridge 300of the aerosol delivery device 100 (see, FIG. 1). This may pull airthrough an opening in the control body 200 (see, e.g., FIG. 2) or in thecartridge 300. For example, in one embodiment an opening may be definedbetween the coupler 202 and the outer body 204 of the control body 200(see, e.g., FIG. 2), as described in U.S. Pat. No. 9,220,302 to DePianoet al., which is incorporated herein by reference in its entirety.However, the flow of air may be received through other parts of theaerosol delivery device 100 in other embodiments. As noted above, insome embodiments the cartridge 300 may include the flow director 308.The flow director 308 may be configured to direct the flow of airreceived from the control body 200 to the heating element 326 of theatomizer 310.

A sensor in the aerosol delivery device 100 (e.g., the flow sensor 210in the control body 200; see, FIG. 2) may sense the puff. When the puffis sensed, the control body 200 may direct current to the heatingelement 326 through a circuit including the first heating terminal 320and the second heating terminal 321. Accordingly, the heating element326 may vaporize the aerosol precursor composition directed to anaerosolization zone from the reservoir 312 by the liquid transportelement 324. Thus, the mouthpiece 326 may allow passage of air andentrained vapor (i.e., the components of the aerosol precursorcomposition in an inhalable form) from the cartridge 300 to a consumerdrawing thereon.

Various other details with respect to the components that may beincluded in the cartridge 300 are provided, for example, in U.S. Pat.App. Pub. No. 2014/0261495 to DePiano et al., which is incorporatedherein by reference in its entirety. Additional components that may beincluded in the cartridge 300 and details relating thereto are provided,for example, in U.S. Pat. Pub. No. 2015/0335071 to Brinkley et al.,which is incorporated herein by reference in its entirety.

Various components of an aerosol delivery device according to thepresent disclosure can be chosen from components described in the artand commercially available. Reference is made for example to thereservoir and heater system for controllable delivery of multipleaerosolizable materials in an electronic smoking article disclosed inU.S. Pat. App. Pub. No. 2014/0000638 to Sebastian et al., which isincorporated herein by reference in its entirety.

In another embodiment substantially the entirety of the cartridge may beformed from one or more carbon materials, which may provide advantagesin terms of biodegradability and absence of wires. In this regard, theheating element may comprise carbon foam, the reservoir may comprisecarbonized fabric, and graphite may be employed to form an electricalconnection with the power source and control component. An exampleembodiment of a carbon-based cartridge is provided in U.S. Pat. App.Pub. No. 2013/0255702 to Griffith et al., which is incorporated hereinby reference in its entirety.

However, in some embodiments it may be desirable to provide aerosoldelivery devices with alternative configurations. In this regard, FIGS.4 and 5 illustrate a cartridge 400 according to an additional exampleembodiment of the present disclosure. FIG. 4 illustrates the cartridgein an exploded configuration. FIG. 5 illustrates the cartridge 400 in anassembled configuration. Where not otherwise described and/orillustrated, the components of the cartridge 400 may be substantiallysimilar to, or the same as, corresponding components described above inrelation to FIG. 1 through FIG. 3.

As illustrated, the cartridge 400 may include a base 402, a flowdirector 408, an atomizer 410, an outer body 414, and a mouthpiece 416.A first end of the outer body 414 may engage the base 402. An opposingsecond end of the outer body 414 may engage the mouthpiece 416.

The flow director 408 may extend from a first end 408A at the base 402through the outer body 414 to a second end 408B at the mouthpiece 416.Thereby, as illustrated in FIG. 5, a reservoir 412 may be definedbetween the flow director 408 and the outer body 414. The reservoir 412may define an open space configured to receive an aerosol precursorcomposition. In one or more embodiments, a fibrous substrate may bepresent in at least a portion of the reservoir 412 to hold aerosolprecursor composition similar to the reservoir substrate 312 illustratedin FIG. 3.

The atomizer 410 may be configured to vaporize the aerosol precursorcomposition received from the reservoir 412. In this regard, asillustrated in FIG. 6, the atomizer 410 may include a liquid transportelement 424 and a heating element 426. The heating element 426 maycomprise a wire defining a plurality of coils extending around theliquid transport element 424. Further, the atomizer 410 may includefirst and second connectors 428A, 428B contacting the coils at first andsecond opposing ends of the heating element 426. The connectors 428A,428B may be configured to engage first and second heating terminals 420,421 (see, FIG. 7) in order to supply power thereto.

The atomizer 410 may extend through the flow director 408. Moreparticularly, a longitudinal axis of the liquid transport element 424may extend substantially perpendicularly to a longitudinal axis of theflow director 408 such that the atomizer 410 extends across the flowdirector 408. In this regard, as illustrated in FIG. 7, the flowdirector 408 may include one or more apertures 429A, 429B extendingtherethrough, transverse to a longitudinal aperture 431 extendingthrough the flow director. The atomizer 410 may extend at leastpartially through each of the apertures 429A, 429B such that theatomizer extends across the longitudinal aperture 431.

The liquid transport element 424 may include a capillary channel 430extending therethrough. The capillary channel 430 may be configured toreceive aerosol precursor composition from the reservoir 412. In thisregard, as illustrated in FIG. 7, the capillary channel 430 may be influid communication with the reservoir 412. Accordingly, the aerosolprecursor composition contained in the reservoir 412 may enter theliquid transport element 424 via the capillary channel 430. Further, theliquid transport element 424 may comprise a porous monolith. Forexample, the liquid transport element 424 may comprise a porous ceramicmaterial composed of silica and/or alumina as exemplary materials. Insome examples, where the liquid transport element 424 comprises amixture of silica and alumina then a heater may be utilized. In someinstances, the heater may be in the form of a conductive mesh, ratherthan a heater coil, formed from a plurality of crossing, conductivefilaments that wrap around the liquid transport element 424 in order toprovide a more uniform heat distribution. Example embodiments ofconductive meshes are described in U.S. patent application Ser. No.15/472,839 to Davis et al., filed Mar. 29, 2017, which is incorporatedherein by reference in its entirety.

Alternatively, the porous liquid transport element may also be comprisedof an electrically conducted ceramic (e.g., boron-doped silicon) thatmay act as a semiconductor for which resistance is controllable. Assuch, the liquid transport element may act as the heating element,thereby forgoing the necessity of a heating coil with a plurality ofcoils and desirably extending a lifetime of the atomizer. Accordingly,the aerosol precursor composition may be wicked from the capillarychannel 430 generally radially outwardly such that the liquid transportelement 424 is saturated and such that the aerosol precursor compositionreaches the heating element 426.

The cartridge 400 may be coupled to a control body such as the controlbody 200 of FIG. 2. The control body 200 may verify that the cartridge400 is genuine and/or perform other functions (e.g., preventing furtherheating of the heating element 426 after a predetermined number ofcumulative seconds of heating have occurred, which may correspond to asubstantially empty cartridge) by communicating with an electroniccomponent 406 via an electronic component terminal 404. Thereafter, whenthe flow sensor 210 (see, FIG. 2) of the control body 200 detects a puffon the cartridge 400, the control body 200 may direct current from theelectrical power source 216 (see, FIG. 2) to the cartridge. Theelectrical current may thereby be directed through the first and secondheating terminals 420, 421 to the first and second connectors 428A,428B.

In some embodiments, as illustrated, the first and second heatingterminals 420, 421 may extend at least partially through the flowdirector 408. For example, the first and second heating terminals 420,421 may be molded into the flow director 408 (e.g., in-molded in theflow director during the formation thereof) and extend along at least aportion of the length thereof. By way of further example, the first andsecond heating terminals 420, 421 may extend along a portion of a lengththereof and terminate at a location at which the atomizer 410 extendsacross the flow director 408. Thereby, the first and second heatingterminals 420, 421 may contact the first and second connectors 428A,428B, respectively, without blocking the apertures 429A, 429B in theflow director 408 through which the atomizer 410 extends. The other endsof the first and second heating terminals 420, 421 and the outer end ofthe electronic component terminal 404 may extend through openingsdefined in the base 402 such that the ends are exposed and configuredfor engagement with corresponding electrical contacts of a control body.

Accordingly, the electrical current may be directed through the heatingelement 426, in order to produce heat (e.g., via joule heating), or maybe conducted directly through the liquid transport element. The heat maybe transferred to the aerosol precursor composition directed through theliquid transport element 424 such that a vapor is produced inside of theflow director 408. The vapor may join with air directed through the flowdirector 408 and travel to a user via the mouthpiece 416 (see, e.g.,FIG. 8). More particular, the vapor may be produced by the atomizer 410within the longitudinal aperture 431 extending through the flow director408. Thereby, by configuring the atomizer 410 such that it extendsthrough the flow director 408, provision of a separate atomizationcavity may not be necessary. In other words, by producing the vaporwithin the flow director 408, it may not be necessary to include aseparate atomization cavity upstream or downstream of the flow director.Accordingly, the capacity of the reservoir 412 for a given cartridgesize may be relatively larger.

In some embodiments the longitudinal aperture 431 may define asubstantially constant cross-section, perpendicular to the longitudinallength of the flow director 408, at each location along the length ofthe flow director. Further, the base 402 may define a base opening 433that may match a size and shape of the longitudinal aperture 431extending through the flow director 408. Additionally, the flow director408 may extend through the mouthpiece 416 (see, e.g., FIG. 8) or matewith an aperture in the mouthpiece having the same size and shape of thelongitudinal aperture 431 extending the flow director. Accordingly, asmooth flow path may be defined through the cartridge 400 so as to allowflow therethrough with reduced pressure drop.

As noted above, the reservoir 412 may define an open space configured toreceive an aerosol precursor composition. The reservoir 412 may besealed such that aerosol precursor composition cannot escape therefromother than through the atomizer 410 in the manner described herein. Inthis regard, the atomizer 410, and more particularly, the first andsecond connectors 428A, 428B, may engage the apertures 429A, 429Bdefined through the flow director 408 and through which the atomizerextends. For example, the first and second connectors 428A, 428B mayrespectively engage one of the apertures 429A, 429B via press fit.Thereby, the atomizer 410 may be sealed with respect to the flowdirector 408.

Further, the outer body 414 may be sealed to the mouthpiece 416 and afirst end of the flow director 408 may be sealed to the mouthpiece. Forexample, the mouthpiece 416 may be ultrasonically welded to the outerbody 414 and the flow director 408. Additionally, the outer body 414 maybe sealed to the base 402. For example, in some embodiments the outerbody 414 may be ultrasonically welded to the base 402.

However, in other embodiments it may be desirable to provide alternativemechanisms for sealing the reservoir 412. For example, it may bedesirable to configure the cartridge 400 such that the atomizer 410 isremovable. However, the atomizer 410 may be irremovably engaged with theflow director 408. Further, the flow director 408 may be irremovablyengaged with the base 402 (e.g., ultrasonically welded, adhesivelyattached, or otherwise substantially permanently connected thereto). Assuch, replacement of the atomizer 410 may involve replacement of anassembly including the atomizer, the flow director 408, the first andsecond heating terminals 420, 421, the electronic component 406 (whichmay be received in a compartment defined between the base and the flowdirector), the electronic component terminal 404, and the base 402.

Accordingly, these components may be configured to be removable from aremainder of the cartridge 400. For example, as illustrated in FIG. 7,the base 402 may include a plurality of threads 402A configured toengage a plurality of threads 414A of the outer body 414 such that theouter body engages the base via threaded engagement. Although thethreads 402A, 414A may form a seal, in some embodiments the cartridge400 may further comprise a sealing member configured to seal the outerbody 414 to the base 402. For example, an O-ring 432, which may comprisesilicone or other resilient material, may extend around the base 402 andmay be compressed between the outer body 414 and the base as the base isthreaded into engagement with the outer body.

Further, the flow director 408 may releasably engage the mouthpiece 416.For example, as illustrated in FIG. 8, the flow director 408 may includea plurality of threads 408A configured to engage a plurality of threads416A of the mouthpiece 416 such that the flow director engages themouthpiece via threaded engagement. Although the threads 408A, 416A mayform a seal, in some embodiments the cartridge 400 may further comprisea sealing member configured to seal the flow director 408 to themouthpiece 416. For example, an O-ring 434, which may comprise siliconeor other resilient material, may extend around the flow director 408 andmay be compressed between the flow director and the mouthpiece as theflow director is threaded into engagement with the mouthpiece.

As may be understood, the flow director 408 may threadingly engage themouthpiece 416 (see, FIG. 8) simultaneously with the base 402threadingly engaging the outer body 414 (see, FIG. 7). Further, a pitchof the threads 408A of the flow director 408 and the threads 416A of themouthpiece 416 may be equal to a pitch of the threads 402A of the base402 and the threads 414A of the outer body 414 to allow simultaneousengagement of the flow director and the mouthpiece and the base and theouter body without one set of threads binding before the other, therebyallowing the threads to form a seal by themselves and/or compressing theO-rings 432, 434 to form a seal.

Accordingly, by employing the threads 402A, 408A, 414A, 416A, thecartridge 400 may be configured such that an assembly including theatomizer 410 may be removed and replaced. In this regard, the assemblyincluding the atomizer 410 may be replaced when the useful life of theatomizer is complete, or the assembly may be replaced with a differingassembly including a differing atomizer that may, for example, beconfigured to produce a greater or lesser amount of aerosol with eachpuff.

As noted above, in some embodiments an assembly including the atomizer410 may be replaceable such that a new atomizer may be provided when theatomizer reaches the end of its useable life. In this regard, in someembodiments the cartridge 400 may be refillable such that the cartridge400 may be repeatedly reused.

Thus, the cartridge 400 may include features configured to facilitaterefilling. For example, as illustrated in FIG. 7, the base 402 maydefine one or more fill ports 436. Thus, the open space defined by thereservoir 412 within the outer housing 414 may receive aerosol precursorcomposition directed through the one or more fill ports 436. Further,the one or more fill ports 436 may respectively comprise a one-way valve438. The one-way valves 438 may be configured to allow flow of theaerosol precursor composition through the fill ports 436 into thereservoir 412, and prevent flow outwardly therefrom. For example, theone-way valves 438 may comprise diaphragm check valves, which may beformed from silicone or other resilient material and which may be biasedto a closed configuration. Accordingly, a nozzle or extension of arefilling bottle may engage the filling port(s) 436 and/or the one wayvalve(s) 438 and direct aerosol precursor composition therethrough torefill the cartridge 400. In some embodiments the outer body 414 may betransparent or translucent along at least a portion thereof, such that auser may view the quantity of aerosol precursor composition containedtherein, which may be useful to determine the level of aerosol precursorcomposition in the reservoir 412 during use and refilling of thecartridge 400.

Example embodiments of one-way valves that may be included in thecartridge 400 and associated refilling bottles and other aerosolprecursor composition refilling components are described in U.S. patentapplication Ser. No. 15/165,928 to Sebastian et al., filed May 26, 2016and U.S. Pat. Appl. Pub. No. 2016/0217882 to Davis et al., which areincorporated herein by reference in their entireties. Further, U.S. Pat.Appl. Pub. No. 2017/0013880 to O'Brien et al., discloses an aerosoldelivery device including a refillable reservoir and a container forrefilling the reservoir, and is incorporated herein by reference in itsentirety.

In some embodiments the refilling bottle may threadingly engage thecartridge, snap into engagement therewith, or otherwise create a secureconnection with the cartridge. The refilling bottle may then dispensethe aerosol precursor composition into the cartridge by pumping orsqueezing the refilling bottle, or by allowing pressurized fluid withinthe refilling bottle to expel the aerosol precursor composition into thecartridge. In some embodiments the filling port(s) may be configured toreceive aerosol precursor composition from a refilling bottle that isalso configured to refill a so-called “tank,” which defines a relativelylarge reservoir for an aerosol delivery device. For example, the fillingports may be sized and configured to receive the nozzle of a tankrefilling bottle, or the tank refilling bottle may be provided with asecond nozzle configured to engage the filling port of the cartridge.Accordingly, the reservoir of the cartridge may be refilled withembodiments of refilling bottles that may be employed to refill multipletypes of aerosol delivery devices.

Thus, the cartridge of the present disclosure may be refilled andreused. As may be understood, reuse of the cartridge may provide costsavings and reduce the amount of waste associated with use of thecartridge as compared to single-use disposable cartridges. As notedabove, cartridges for aerosol delivery devices have traditionallyemployed fibrous wicks to transport aerosol precursor composition to aheating element. In view of the relatively short lifespan of suck wicks,cartridges have not generally been configured to be refillable. However,by employing a porous monolith as the liquid transport element, and/orby configuring the atomizer such that it is replaceable, and/orutilizing the liquid transport element itself as the heater, asdescribed herein, the cartridge may be refilled and reused repeatedly.

In an additional embodiment an aerosol delivery device operation methodis provided. As illustrated in FIG. 9, the method may include retainingan aerosol precursor composition in a reservoir defined between a flowdirector and an outer body, the flow director extending between a firstflow director end and a second flow director end at operation 502.Further, the method may include directing the aerosol precursorcomposition from the reservoir through a liquid transport element of anatomizer extending through the flow director at a position between thefirst flow director end and the second flow director end at operation504. The method may additionally include receiving an electrical currentthrough a heating element of the atomizer at operation 506. The methodmay further include vaporizing at least a portion of the aerosolprecursor composition to produce an aerosol within the flow director atoperation 508.

In some embodiments the method may further include receiving the aerosolprecursor composition through one or more fill ports defined in a base.Directing the aerosol precursor composition through the liquid transportelement at operation 504 may include directing the aerosol precursorcomposition through a capillary channel. Directing the aerosol precursorcomposition through the liquid transport element at operation 504 mayfurther include directing the aerosol precursor composition through aporous monolith to the heating element.

In some embodiments receiving the electrical current through the heatingelement at operation 506 may include receiving the electrical currentthrough a wire defining a plurality of coils extending around the liquidtransport element. The method may further include directing the aerosolout of the flow director through a mouthpiece. Additionally, the methodmay include retaining the aerosol precursor composition in the reservoirwith a seal between the outer body and the base. Further, the method mayinclude retaining the aerosol precursor composition in the reservoirwith a seal between the mouthpiece and the outer body and a seal betweenthe mouthpiece and the flow director.

Many modifications and other embodiments of the disclosure will come tomind to one skilled in the art to which this disclosure pertains havingthe benefit of the teachings presented in the foregoing descriptions andthe associated drawings. Therefore, it is to be understood that thedisclosure is not to be limited to the specific embodiments disclosedherein and that modifications and other embodiments are intended to beincluded within the scope of the appended claims. Although specificterms are employed herein, they are used in a generic and descriptivesense only and not for purposes of limitation.

1. An aerosol delivery device, comprising: an outer body; a base; a flowdirector extending from a first flow director end to a second flowdirector end through the outer body such that a reservoir is definedbetween the flow director and the outer body, the reservoir defining anopen space configured to receive an aerosol precursor composition; andan atomizer extending through the flow director at a position betweenthe first flow director end and the second flow director end, theatomizer including a liquid transport element and a heating elementconfigured to vaporize at least a portion of the aerosol precursorcomposition to produce an aerosol within the flow director.
 2. Theaerosol delivery device of claim 1, wherein the liquid transport elementcomprises a capillary channel extending therethrough.
 3. The aerosoldelivery device of claim 2, wherein the liquid transport elementcomprises a porous monolith.
 4. The aerosol delivery device of claim 3,wherein the heating element comprises a wire defining a plurality ofcoils extending around the liquid transport element.
 5. The aerosoldelivery device of claim 4, further comprising first and secondconnectors contacting the coils at first and second opposing ends of theheating element.
 6. The aerosol delivery device of claim 1, wherein alongitudinal axis of the liquid transport element extends substantiallyperpendicularly to a longitudinal axis of the flow director.
 7. Theaerosol delivery device of claim 1, wherein the outer body is sealed tothe base.
 8. The aerosol delivery device of claim 7, wherein the outerbody engages the base via threaded engagement.
 9. The aerosol deliverydevice of claim 8, further comprising an O-ring is compressed betweenthe outer body and the base.
 10. The aerosol delivery device of claim 1,further comprising a mouthpiece, wherein the mouthpiece is sealed to theouter body and the flow director.
 11. The aerosol delivery device ofclaim 1, wherein the base comprises one or more fill ports configured toreceive the aerosol precursor composition therethrough.
 12. The aerosoldelivery device of claim 1, wherein the atomizer is sealed to the flowdirector.
 13. An aerosol delivery device operation method, comprising:retaining an aerosol precursor composition in a reservoir definedbetween a flow director and an outer body, the flow director extendingbetween a first flow director end and a second flow director end;directing the aerosol precursor composition from the reservoir through aliquid transport element of an atomizer extending through the flowdirector at a position between the first flow director end and thesecond flow director end; receiving an electrical current through aheating element of the atomizer; and vaporizing at least a portion ofthe aerosol precursor composition to produce an aerosol within the flowdirector.
 14. The aerosol delivery device operation method of claim 13,further comprising receiving the aerosol precursor composition throughone or more fill ports defined in a base.
 15. The aerosol deliverydevice operation method of claim 13, wherein directing the aerosolprecursor composition through the liquid transport element comprisesdirecting the aerosol precursor composition through a capillary channel.16. The aerosol delivery device operation method of claim 15, whereindirecting the aerosol precursor composition through the liquid transportelement further comprises directing the aerosol precursor compositionthrough a porous monolith to the heating element.
 17. The aerosoldelivery device operation method of claim 13, wherein receiving theelectrical current through the heating element comprises receiving theelectrical current through a wire defining a plurality of coilsextending around the liquid transport element.
 18. The aerosol deliverydevice operation method of claim 13, further comprising directing theaerosol out of the flow director through a mouthpiece.
 19. The aerosoldelivery device operation method of claim 13, further comprisingretaining the aerosol precursor composition in the reservoir with a sealbetween the outer body and the base.
 20. The aerosol delivery deviceoperation method of claim 13, further comprising retaining the aerosolprecursor composition in the reservoir with a seal between themouthpiece and the outer body and a seal between the mouthpiece and theflow director.